Electrical connector cover



D 6, 96 P. K. CAMPBELL 3,484,541

ELECTRICAL CONNECTOR COVER I Filed Sept. 27. 1968 2 Sheets-Sheet 1 FIG.1

United States Patent O 3,484,541 ELECTRICAL CONNECTOR COVER Paul K.Campbell, Birmingham, Ala., assignor t Anderson Electric Corporation,Leeds, Ala., a corporation of Alabama Filed Sept. 27, 1968, Ser. No.763,328 Int. Cl. H01b 17/00; H02g /08 U.S. Cl. 174--138 10 ClaimsABSTRACT OF THE DISCLOSURE BACKGROUND OF THE INVENTION The invention isin the field of insulating covers for electrical connectors, and relatesparticularly to two-section hinged covers for uninsulated crimped cableconnectors.

Insulated electrical cables are conventionally connected together bycrimping a crimpable connector to bared portions of the cables with acompression crimping tool. While the cables themselves may beelectrically insulated other than at their ends where they areconnected, usually such connectors are of bare, uninsulated metal. Thus,a shock hazard is presented where, for example, it is desired to employsuch a connector to connect a tap conductor to a main line conductor toprovide electrical service to a dwelling. Accordingly, it is desirableto place an insulating cover around the connector and bared margins ofthe conductors so that bare metal carrying high voltages is not exposedto inadvertent contact.

Although two-section hinged covers formed of a plastic insulatingmaterial have been developed, most have limited range-taking capability,i.e., they will accommodate at most only a few sizes of connectors andconductors. in addition, such covers have not provided sufficient1ongitudinal and lateral confinement of the connector and thereby permitthe cover to slide or be pushed along the conductors until the connectorabuts the end of the cover, or permit the cover to rattle as where it isblown about by wind. With such covers, great care must be taken tolocate the connector in the center of the cover so that the cover cannotslip completely off of the connector or permit a bared portion of theconnector to protrude from or be exposed at one end of the cover. Bothof these conditio s defeat the insulating purpose of the cover bypermitting exposure of part of the uninsulated portions of theconductors or connector thereby increasing the possibility of shockhazard and the likelihood of corrosion and accidental electrical contactwith external objects. In addition, prior art covers under someconditions may accumulate moisture and thereby defeat the insulatingpurpose of the cover and promote corrosion of the connector. Anotherdisadvantage of some covers has been the tendency of their latches tobecome disengaged when the cover halves are under tension thuspermitting the cover to fall off or become undesirably loose.

SUMMARY OF THE INVENTION Among the several objects of the invention maybe noted the provision of an improved insulating electrical ICC coverfor tightly containing crimped connectors in a wide range of sizes; theprovision of such a cover which snugly grips a connector to imposefrictional resistance against endwise or lateral shifting of the coveron the connector; the provision of such a cover which positively limitsendwise movement of the cover on a connector; the provision of such acover which prevents latching together of the cover halves unless thecover is centered on the connector; and the provision of such a coverwith latches having inclined mating surfaces for preventingdisengagement under tension. Other objects and features will be in partapparent and in part pointed out hereinafter.

Briefly, a connector cover constructed in accordance with the presentinvention comprises a pair of engageable hinged cover halves formed of aresilient insulating material with means for latching the cover halvesto define a compartment therebetwe'en. In addition, the ends of thecover are adapted to provide openings conforming generally to the crosssection of connected conductors extending through the ends. At least onecover half has a concave wall portion for engaging the connector toimpose frictional resistance against endwise or lateral shifting of thecover on the connector. Each of the cover halves is elongate and isprovided with a pair of end stops spaced from its ends for positivelylimiting endwise movement of the connector.

The concave wall of the present cover therefore securely engages theconnector by flexing outwardly thereby avoiding lateral and longitudinalmovement of the cover relative to the connector. Latches with inclinedmating surfaces firmly lock the cover halves together, therebyeliminating inadvertent opening and dislodging of the cover.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a plan view of a cover ofthe present invention in an open position;

FIG. 2 is a side view of the cover taken on line 2--2 of FIG. 1;

FIG. 3 is an end view of the cover taken on line 33 of FIG. 1;

FIG. 4 is a longitudinal section of the cover when closed with aconnector therein, conductors extending through the cover ends from theconnector;

FIG. 5 is a transverse section of the closed cover of FIG. 4, taken online 5-5 of FIG. 4; and

FIG. 6 is a detail section of the latch assembly of the present cover.

Corresponding reference characters indicate corresponding partsthroughout the several views of the drawings.

DESCRIPTION OF THE PREFERRED EMBODIMENT Referring now to the drawings,and particularly to FIGS. l3, the present connector cover 1 ispreferably formed as a unitary injection molding of a relativelyflexible, resilient plastic or synthetic resin material such aspolyethylene (e.g., such as obtainable under the trade designation 770Mfrom The Dow Chemical Co.) and is comprised of first and secondinterengageable cover halves 3 and 5, respectively, joined together byan integral continuous flexible hinge 7. The cover 1 is adapted to befolded along the hinge 7 for engaging the cover halves 3, 5 to define acompartment interiorly therebetween for enclosing a connector. Latchesconstituted by a plurality of talons 9 and loop retainers 11 are formedrespectively on the first and second cover halves 3, 5 for maintainingthe cover closed. When closed, the cover has an elongate boxlikeconfiguration having a generally rectangular cross section, as seen mostclearly in FIGS. 4 and 5.

Each of the cover halves is generally boat-shaped with generally planarside wall portions 13, 15 and 17, 19,

respectively, and opposed end wall portions 21, 23 and 25, 27,respectively. The end walls 21, 23, 25 and 27 comprising the ends of thecover are fringed. That is, each is constituted by a plurality ofresilient strips 29 extending toward the opposite cover half when thecover is closed so that the cover has ends adapted to provide openingsconforming generally to the cross section of the insulated cables orconductors extending through the ends of the cover. The strips 29 thusengage the periphery of these conductors and are capable ofaccommodating a Wide range of conductor diameters. Each of the coverhalves is further constituted by a generally planar main wall surfaceincluding a longitudinal wall portion 31, 33. The longitudinal and sidewall portions join in a smoothlycurved, rounded edge.

As best illustrated in FIGS. 2 and 3, the longitudinal walls 31 and 33are provided with pairs of raised end stops comprising transverse raisedribs 35, 35 and 37, 37 spaced inwardly from the end wall portions 21, 23and 25, 27 and extending across the width of the respective coverhalves. Pairs of end stops register when the cover halves are latched.The end stops positively limit longitudinal movement of the coverrelative to a connector enclosed within the compartment formed by cover1 when it is closed. In addition, the registering end stops 37, 37 and35, 35 interfere with a connector to prevent the cover from being closedif the connector is not placed centrally in the compartment between theend stops. Because of the deeper section of the end stops 35, 35, 37, 37and because they have sufficient thickness so that they are relativelyrigid, the end stops are stiif enough to resist being bent over by aconnector if it is attempted to close the cover with the connectorinterfering with the registering pairs of end stops.

Each of the cover halves has a wall portion 39, 39' which is bowedlaterally between the end stops 35, 37 and 35, 37', respectively. Eachconcave wall portion 39, 39' has longitudinal edges which curve smoothlyinto and join the side wall portions generally in the plane of eachcover half including its respective longitudinal wall portions 31, 33.The concave wall portion of each cover half is therefore concave withrespect to the exterior of the cover and these portions are insubstantial registry with each other when the cover is closed thereby toengage the connector and impose frictional resistance against endwise orlateral shifting of the cover on the connector. Although each of thecover halves is shown as having a concave wall portion, it will beunderstood that only one cover half might be provided with a concavewall portion with some reduction of the range-taking capability of thecover with respect to the sizes of connectors with which it is to beused.

FIGS. and 6 illustrate latches for the cover halves which are providedwith inclined mating surfaces 41 and 43 formed respectively on thetalons 9 and loop retainers 11 comprising the latches. The talons 9 rideup the inclined mating surface 43 of the loop retainers 11 when theopposing cover halves are forced apart by the engagement with aconnector of the concave wall portions of the cover halves. Thus thelatches are even more tightly latched for resisting disengagement undertension. Positive latching of the cover halves is therefore assured andthere is avoided the possibility of separation under tension as iscommon with other conventional latching means. It should be noted thatthe pair of latches toward the ends of the cover halves are positionedin transverse alignment with the end stops 35 and 37 (see FIG. 1) toprevent latching if a connector is interposed between registering endstops.

Each of the cover halves is provided with drainage notches 45, 47 and49, 51 adjacent an edge and disposed at the opposite ends of the cover.The notches are adapted to mate upon closing of the cover halves to forma plurality of drainage apertures. Each of the notches 45, 47 and 49, 51is provided with a raised peripheral boss 53 for preventing waterrunning along the surface of-the cover from entering the compartmentthrough the apertures.

Referring now to FIG. 4, there is illustrated a splice type compressionconnector 55 which interconnects conductors 57 and 59. As isconventional, ends 61 and 63 of conductors 57 and 59 are stripped ofinsulation and are inserted into the opposite ends of connector 55, thelatter being formed of a malleable electrically conductive metal such asaluminum. Before compression, connector 55 has a substantially constantthickness. After conductors 57, 59 are placed in position, anyconventional compression tool is fitted over connector 55 andmanipulated to crimp the connector body securely to the bared ends 61and 63 located internally thereof. During this crimping operation,portions of the connector body are upset, i.e., swaged, but otherportions are not, these latter portions having substantially the samethickness as before the crimping operation. To apply cover 1 to thecrimp-connected conductors 57 and 59, it is placed over the connector 55so that the connector is between the end stops 35, 37 in either of thecover halves. The other cover half is closed over connector 55 andlatched by talons 9 and loop retainers 11. The conductors 57 and 59extend outwardly through the openings provided by the fringed end walls21, 25 and 23, 27 formed by the resilient strips 29.

The cover may be produced in several different sizes, each accommodatinga wide range of connector types and sizes. For any given cover size, theconnectors with which the cover may be used must have a minimumthickness which should be greater than the distance between theinnermost edges of the registered pairs of end stops 35, 35 and 37, 37.When a connector 55 is enclosed when centrally located between the endstops 35 and 37, endwise movement of the cover is avoided because thecrimped connector is of greater thickness than the opening between eachpair of end stops. Therefore, when a connector 55 is disposed within thecover, the connector bears against the concave walls 39 forcing them toflex or bulge outwardly as in FIG. 4. The concave walls 39 snugly gripthe connector 55 within the compartment and thereby impose frictionalresistance against endwise or lateral shifting of the cover on theconnector due to the wind or other causes. Furthermore, since thelatches 9 and 11 are in tranverse alignment with the end stops 35 and37, the user, such as a lineman, will be unable to latch the coverhalves together unless the connector 55 is within the desired zonebetween end stops 35 and 37. When the cover is thus correctly positionedthe talons 9 and loop retainers 11 may be latched. Since the connector55 is of greater thickness than the internal dimension of thecompartment the cover halves are tensioned oppositely towards an openposition. This causes the inclined mating surfaces 41, 43 of the latchtalons 9 and 11 to wedge firmly together to latch the cover halvessecurely.

It is to be understood that the covers of the present invention areuseful with many types of crimped connections as well as bolt-typeconnectors, and that parallel connections, such as tap connections to amain conductor as well as splice connections, are conveniently insulatedby covers of this invention.

In view of the above, it will be seen that the several objects of thepresent invention are achieved and other advantageous results attained.

As various changes could be made in the above constructions withoutdeparting from the gist of the invention, it is intended that all mattercontained in the above description or shown in the accompanying drawingsshall be interpreted as illustrative.

What is claimed is:

1. An insulating cover for an electrical connector comprising a pair ofinterengageable cover halves formed of a resilient insulating material,means for latching said cover halves together to define a compartmentinteriorly therebetw'een, said cover having ends adapted to provideopenings conforming generally to the cross section of conductorsextending through said ends from the connector, at least one cover halfhaving a pair of end stops spaced from its ends for limiting endwisemovement of the cover on the connector, the last said cover half havinga wall portion concave with respect to the exterior of the cover andextending substantially from end stop to end stop for engaging theconnector to impose frictional resistance against endwise or lateralshifting of the cover on the connector.

2. A cover as in claim 1 wherein said cover halves are hinged together.

3. A cover as in claim 1 wherein each of said cover halves has end stopsand has a concave wall portion extending substantially from end stop toend stop, each of said wall portions being bowed laterally relative tothe length of said conductor to provide opposing concave wall portions.

4. A cover as in claim 3 wherein said cover, when said cover halves arelatched together, is generally rectangular in cross section and saidconcave portions and ribs are in substantial registry.

5. A cover as in claim 4 wherein the ends of the cover are fringed.

6. A cover as in claim 4 wherein said latching means comprises aplurality of talons formed on one of the cover halves and acorresponding plurality of loop retainers formed on the other of saidcover halves, at least one mating pair of talons and loop retainersbeing laterally aligned with one of said end stops.

7. A cover as in claim 1 wherein each of said end stops comprises atransverse rib spaced inwardly from an end of the cover half andextending across the cover half, the corresponding end stops of each ofthe cover halves registering when the cover halves are latched.

8. A cover as in claim 7 wherein said end stops have a thicknesssufficient to be relatively rigid and the space between opposing endstops when the cover halves are latched together is less than thediameter of the connector whereby the cover halves are prevented frombeing latched together if the connector is interposed between theregistered end stops.

9. A cover as in claim 1 wherein said latching means comprises aplurality of talons formed on one of said cover halves and acorresponding plurality of loop retainers formed on the other of saidcover halves, the talons and retainers having inclined mating surfacesfor preventing disengagement of the latches under tension.

10. A cover as in claim 1 wherein each of said cover halves is providedwith at least one drainage notch at an edge, the notches mating when thecover halves are latched to form a drainage aperture.

References Cited UNITED STATES PATENTS 3,183,302 5/1965 Wochner et al.17492 X 3,249,679 5/ 1966 Bogese.

3,278,674 10/1966 Matthysse et al. 174-92 X 3,325,591 6/1967 Wnhl 174-92X LARAMlE ASKIN, Primary Examiner US. Cl. XR, 174-9;

